Emerson 7003M User Manual

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Operator Manual

748223-K June 2002

Model 7003M

Percent Oxygen Analyzer

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ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical rep-

resentative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and maintenance of

the product.

• Install your equipment as specified in the Installation Instructions of the appropriate Instruc- tion Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without notice.

Ryton® is a registered trademark of Phillips Petroleum Co.

Emerson Process Management

Rosemount Analytical Inc. Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com

http://www.processanalytic.com

Model 7003M

PREFACE...........................................................................................................................................P-1

Definitions ...........................................................................................................................................P-1

Safety Summary .................................................................................................................................P-2

Documentation....................................................................................................................................P-5

Compliances .......................................................................................................................................P-5

1-0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1

1-1 Overview................................................................................................................................1-1

1-2 Principle of Measurement......................................................................................................1-1

1-3 Sensors..................................................................................................................................1-1

1-4 Conditions Affecting Measurement .......................................................................................1-2

a. Gas Composition.............................................................................................................1-2

b. Sample and Cal Gas Pressures......................................................................................1-2

c. Environmental Factors ....................................................................................................1-2

1-5 Features.................................................................................................................................1-3

1-6 Specifications ........................................................................................................................1-4

a. Performance....................................................................................................................1-4

b. Physical...........................................................................................................................1-4

c. Electrical..........................................................................................................................1-5

d. Sensors ...........................................................................................................................1-5

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2-0 INSTALLATION ....................................................................................................................2-1

2-1 Unpacking..............................................................................................................................2-1

2-2 Storage ..................................................................................................................................2-1

2-3 Analyzer Installation ..............................................................................................................2-1

2-4 Sensor Installation .................................................................................................................2-1

a. Analyzer/Sensor Jumper Configuration ..........................................................................2-1

2-5 Electrical Connections ...........................................................................................................2-3

a. Sensor Cable ..................................................................................................................2-4

b. Power Connections.........................................................................................................2-4

c. Current Output Connections ...........................................................................................2-6

d. Voltage Output Connections ...........................................................................................2-6

2-6 Relay Contacts for Alarms or ON/OFF-Controls ...................................................................2-8

3-0 OPERATION .........................................................................................................................3-1

3-1 Overview................................................................................................................................3-1

3-2 Keypad Operation..................................................................................................................3-1

a. Single and Double Keystroke..........................................................................................3-3

b. Display Prompts ..............................................................................................................3-4

c. Error Messages...............................................................................................................3-6

d. Automatic Return to RUN Mode .....................................................................................3-7

e. Preventing Unauthorized Access....................................................................................3-7

f. Sensor Equilibrium..........................................................................................................3-7

3-3 Start-Up .................................................................................................................................3-8

a. Initial Power-Up...............................................................................................................3-8

b. System Restart................................................................................................................3-9

c. Automatic Restart - Due to Power Failure ......................................................................3-9

d. Manual Restart................................................................................................................3-9

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3-4 Run Mode ..............................................................................................................................3-10

a. Display Oxygen Concentration/Sensor Temperature .....................................................3-10

b. Acknowledge Alarms ......................................................................................................3-10

c. Access Other Modes.......................................................................................................3-10

3-5 Setup Mode ...........................................................................................................................3-11

a. Security Code..................................................................................................................3-13

b. Current Output Range - 0-20mA or 4-20mA................................................................3-13

c. Range Endpoint Adjustments .........................................................................................3-13

d. Zero Offset Adjustment ...................................................................................................3-15

3-6 Alarm Mode vs. ON/OFF-Control Mode ................................................................................3-16

a. Relay Configured as Alarm .............................................................................................3-16

b. Relay Configured as ON/OFF-Controller ........................................................................3-16

c. Relay Contacts................................................................................................................3-18

d. Fail Safe Operation .........................................................................................................3-18

e. Relay Reset Upon Fatal Error.........................................................................................3-18

f. Pressure Effects on Alarms ............................................................................................3-18

g. Setting Alarm and ON/OFF-Controller Relays................................................................3-18

h. Setting Alarm Setpoints ..................................................................................................3-18

i. Setting Alarm ON and OFF Levels .................................................................................3-19

Model 7003M

4-0 CALIBRATION AND ADJUSTMENTS.................................................................................4-1

4-1 Frequency of Calibration .......................................................................................................4-1

4-2 Calibration mode ...................................................................................................................4-1

a. Zero Calibration...............................................................................................................4-1

b. Span Calibration..............................................................................................................4-1

c. Pressure Compensation - Correction for Constant Pressure Differences......................4-4

4-3 Hold Mode .............................................................................................................................4-5

4-4 Diagnostics Mode ..................................................................................................................4-8

a. Raw Sensor Voltage .......................................................................................................4-8

b. Test Current Output ........................................................................................................4-8

c. Linearizing Current Output ..............................................................................................4-8

d. Test Alarm Relays...........................................................................................................4-10

4-5 Adjustments And Settings .....................................................................................................4-10

5-0 THEORY................................................................................................................................5-1

5-1 Principles Of Operation .........................................................................................................5-1

a. Electrochemical Theory ..................................................................................................5-1

5-2 Effects of Sample Conditions ................................................................................................5-1

a. Barometric Pressure .......................................................................................................5-1

b. Humidity ..........................................................................................................................5-1

c. Sample Temperature ......................................................................................................5-1

d. Interfering Gases.............................................................................................................5-2

5-3 Circuit Descriptions................................................................................................................5-2

a. Signal Board....................................................................................................................5-2

b. Power Supply Board .......................................................................................................5-2

c. Microprocessor Board .....................................................................................................5-2

d. Alarm Circuits..................................................................................................................5-2

6-0 ROUTINE SERVICING AND TROUBLESHOOTING...........................................................6-1

6-1 Routine Servicing ..................................................................................................................6-1

6-2 Troubleshooting.....................................................................................................................6-1

a. Symptoms .......................................................................................................................6-1

ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

7-0 REPLACEMENT PARTS ......................................................................................................7-1

7-1 Circuit Board Replacement Policy .........................................................................................7-1

7-2 Matrix .....................................................................................................................................7-1

7-3 Replacement Parts - Model 7003M.......................................................................................7-2

7-4 Replacement Parts - Sensors................................................................................................7-3

a. Rechargeable Sensors ...................................................................................................7-3

b. Disposable Sensors ........................................................................................................7-4

8-0 RETURN OF MATERIAL ......................................................................................................8-1

8-1 Return Of Material .................................................................................................................8-1

8-2 Customer Service ..................................................................................................................8-1

8-3 Training..................................................................................................................................8-1

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LIST OF ILLUSTRATIONS

Figure 2-1. Sensor Ordering Matrix.......................................................................................... 2-2

Figure 2-2. Model 7003M Rear Panel Connections................................................................. 2-3

Figure 2-3. Power Jumpers and Fuses .................................................................................... 2-5

Figure 2-4. Current Output Connections .................................................................................. 2-7

Figure 3-1. Model 7003M Front Panel Controls and Indicators ............................................... 3-1

Figure 3-2. Model 7003M Operation Flow Diagram................................................................. 3-2

Figure 3-3. SETUP Mode Flowchart ...................................................................................... 3-12

Figure 3-4. Security Access Routine Flowchart ..................................................................... 3-14

Figure 3-5. ALARM Mode Flowchart...................................................................................... 3-17

Figure 3-6. Action of Alarm Relay ON and OFF Setpoints .................................................... 3-19

Figure 4-1. CALIBRATION Mode and PRESSURE COMPENSATION Flowchart.................. 4-3

Figure 4-2. HOLD and DIAGNOSTICS Modes Flowchart ....................................................... 4-7

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Table 2-1. Sensor Cables ....................................................................................................... 2-4

Table 2-2. Analyzer Cable Connections ................................................................................. 2-4

Table 3-1. Key Functions ........................................................................................................ 3-3

Table 3-2. Display Indicators .................................................................................................. 3-3

Table 3-3. Security Access Prompts and Responses............................................................. 3-4

Table 3-4. Alarm Settings Prompts and Responses............................................................... 3-4

Table 3-5. Calibration Prompts and Responses ..................................................................... 3-4

Table 3-6. System Setup Prompts and Responses................................................................ 3-4

Table 3-7. System Hold and Diagnostics Codes .................................................................... 3-5

Table 3-8. Data Displayed in DIAGNOSTICS Mode............................................................... 3-5

Table 3-9. Miscellaneous Prompts and Responses ............................................................... 3-5

Table 3-10. Power ON, Reset Diagnostics Errors (Fatal Errors ............................................... 3-6

Table 3-11. RUN Mode Errors (Non-Fatal Errors ..................................................................... 3-6

Table 3-12. Signal Board Errors ............................................................................................... 3-6

Table 3-13. Microprocessor Errors That Reset The System .................................................... 3-6

Table 3-14. Default Settings at Power-Up ................................................................................ 3-8

Table 3-15. RUN Mode Key Functions ................................................................................... 3-10

Table 3-16. SETUP Mode Key Functions .............................................................................. 3-11

Table 3-17. ALARM Mode Key Functions.............................................................................. 3-16

Table 3-18. Alarm Relay Contact Positions/Terminal Locations............................................. 3-18

Table 4-1. CALIBRATION Mode Key Functions........................................................................1

Table 4-2. Composition of Dry Atmospheric Air...................................................................... 4-2

Table 4-3. Composition of Humid Atmospheric Air................................................................. 4-2

Table 4-4. Barometric Pressure Effect on Apparent Oxygen Concentration ..............................4

Table 4-5. PRESSURE COMPENSATION Mode Key Functions..............................................4

Table 4-6. HOLD Mode Key Functions ......................................................................................5

Table 4-7. Caret Readings...................................................................................................... 4-6

Table 4-8. DIAGNOSTICS Mode Key Functions ................................................................... 4-8

Model 7003M

LIST OF TABLES

LIST OF DRAWINGS

652542 Outline and Mounting – Panel Mount 652543 Outline and Mounting – Wall Mount 652544 Outline and Mounting – Pipe Mount 652682 Pictorial Wiring Diagram 652683 Interconnect Diagram 652699 Installation Drawing

iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Operator Manual

Model 7003M

PREFACE

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Model 7003M Percent Oxygen Analyzer

Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.

DEFINITIONS

The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout this publication.

DANGER .

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Highlights the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

WARNING .

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.

CAUTION.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure, condition or statement.

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Operator Manual

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Model 7003M

SAFETY SUMMARY

If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.

AUTHORIZED PERSONNEL

To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property, all personnel authorized to install, operate and service the this equipment should be thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS.

DANGER.

ELECTRICAL SHOCK HAZARD

Do not operate without doors and covers secure. Servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel.

For safety and proper performance this instrument must be connected to a properly grounded three-wire source of power.

Relay contacts wired to separate power sources must be disconnected before servicing.

This instrument was shipped from the factory set up to operate on either 115 VAC 50/60 Hz, or 230 VAC 50/60 Hz, as specified by sales order. Verification that this voltage is proper for the installation is the responsibility of the purchaser. See Section 2-5b on page 2-4.

WARNING .

OXYGEN LEVEL WILL NOT BE MONITORED

The instrument will not return automatically to the RUN mode from HOLD or DIAGNOSTICS modes. Operator must manually return instrument to RUN mode to continue monitoring oxygen.

WARNING.

ERRONEOUS OXYGEN READINGS

If the pressure compensation function is not applied correctly, erroneous readings can be displayed. The display using span gas during calibration should be the same as the reading using the same gas in RUN mode if the pressure values are correctly entered.

P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Operator Manual

Model 7003M

WARNING.

PARTS INTEGRITY

Tampering or unauthorized substitution of components may adversely affect safety of this product. Use only factory documented components for repair

WARNING.

SENSOR NOT INTRINSICALLY SAFE

The oxygen sensors used with this analyzer are not intrinsically safe. Use of the sensors in or near flammable liquids, gases or vapors or in Class I, Division 1, Hazardous Locations should be carefully evaluated by qualified personnel at the site and is entirely the responsibility of the user.

The sensor is approved as non-incendive for use in Class I, Division 2 locations.

CAUTION .

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HIGH PRESSURE GAS CYLINDERS

This module requires periodic use of pressurized gas. See General Precautions for Handling and Storing High Pressure Gas Cylinders, page P-4

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Model 7003M

GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH

PRESSURE GAS CYLINDERS

Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed Gases" published in 1981

Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202

Used by Permission

1. Never drop cylinders or permit them to strike each other violently.

2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent.

3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in a cylinder stand, and is ready to be used.

4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a suitable hand-truck.

5. Never tamper with safety devices in valves or cylinders.

6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is attached to a pressurized system.

7. No part of cylinder should be subjected to a temperature higher than 125 permitted to come in contact with any part of a compressed gas cylinder.

8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions must be taken to prevent striking an arc against the cylinder.

F (52°C). A flame should never be

P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Operator Manual

Model 7003M

DOCUMENTATION

The following Model 7003M instruction materials are available. Contact Customer Service Center or the local representative to order.

748223 Operator Manual (this document)

COMPLIANCES

The Model 7003M Percent Oxygen Analyzer and Models 4000 and 5000 series sensors are suitable for use in Class I, Groups A, B, C, and D, Division 2 locations per North American electrical codes. Factory Mutual Research (FM) approved under J.I. 1T5AO.AX. Canadian Standards Association (CSA) certified under file LR 93812.

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APPROVED

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P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

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SECTION 1

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

The Model 7003M Percent Oxygen Analyzer continuously monitors the concentration of oxygen in a gaseous sample. It consists of a sensor and the analyzer. The sensor is housed in a chamber assembly and is connected to the analyzer by a shielded multiconductor cable.

The Model 7003M Percent Oxygen Analyzer provides direct digital readout, isolated current

MODE FUNCTION

RUN (see Section 3-4 on page 3-10) Normal monitoring SETUP (see Section 3-5 on page 3-11) Changing parameters ALARM/CONTROL (see Section 3-6 on page 3-16) Set alarms or ON/OFF controllers CALIBRATION (see Section 4-2 on page 4-1) Gas calibration/pressure inputs HOLD (see Section 4-3 on page 4-5) Retain last output value DIAGNOSTICS (see Section 4-4 on page 4-8) Electronics checks

The Model 7003M Percent Oxygen Analyzer is housed in a NEMA 4X (CSA enclosure 4), corrosion resistant housing suitable for panel, pipe or wall mounting.

The analyzer has a microprocessor controlled keyboard for operation. Signals from the remote oxygen and temperature sensors are processed to compute real time oxygen concentration corrected for temperature, constant pressure differences and residual sensor current. The oxygen concentration is compared with user-set alarm parameters, and also generates an isolated 4 to 20 or 0 to 20mA signal. Data is stored in a memory circuit that retains the data in case power is removed.

The analyzer is shipped from the factory configured for operation on either 115 VAC or 230 VAC, 50/60 Hz as specified by the customer when ordered.

output, automatic temperature compensation circuitry, and dual relay contact closures for alarms or ON/OFF control devices as standard features. The alarm ranges can be selected independently from the output range, eliminating the need to readjust alarm setpoints if the range is changed.

The analyzer has six modes of operation:

1-2 PRINCIPLE OF MEASUREMENT

Measurement is based on the electrochemical reaction between oxygen and the sensor cathode which produces a low level electrical current. The sensor signal is proportional to the partial pressure of oxygen present at the membrane. This signal and a thermistor signal are received by the analyzer and processed by the electronics to output a calibrated oxygen signal that is compensated for temperature.

1-3 SENSORS

Rosemount Analytical offers rechargeable and disposable oxygen sensors which can be used with the Model 7003M. These sensors are supplied in kits: Submersion, in-line flow, fast response, and a cell separation kit. Sensors are available constructed of polypropylene or Ryton. See Section 74REPLACEMENT PARTS - SENSORS on page 7-3, for additional information.

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1-4 CONDITIONS AFFECTING MEASUREMENT

Oxygen measurement is affected by the following:

•

Composition of the sampled gas

•

Sample and calibration gas pressures

•

Environment of sensor, cable and analyzer

Each must be considered when calibrating and operating the analyzer to obtain accurate measurements.

a. Gas Composition

Any substance in the sample that significantly interferes or "poisons" the sensor oxygen reading should be removed by a chemical and/or mechanical sample handling system (see Section 5-2 on page 5-1). If ambient air is not used as the span gas, the composition of calibration gases should also be representative of the sample.

The sample and calibration gases must meet certain specifications (see Specifications in Preface) to ensure accurate measurement. Physical parameters that affect measurement include:

b. Sample and Cal Gas Pressures

The sample and calibration gases may be at different pressures as long as the pressure of each remains constant. Any variation in the pressure of either gas will result in an incorrect output reading of the same proportion.

Two methods of sample calibration are recommended:

1. Calibrate at the sample pressure, or

2. Calibrated at a different pressure, and enter the two pressure in the analyzer (Section 4-2c on page 4-4)

Refer to Section 5-2 on page 5-1 for a more detailed discussion of the relationship between gas pressures and apparent oxygen concentration.

c. Environmental Factors

If radio frequency interference (RFI) normally occurs in the operating environment, the sensor cable should be electrically shielded during installation.

•

Pressure

•

Humidity

•

Temperature

•

Gas composition

Also refer to Section 5-2 on page 5-1 for additional information about how gas conditions affect the oxygen measurement.

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

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1-5 FEATURES

Suppressed Ranges

When setting the Model 7003M to a suppressed output range (15 to 25%, etc.), note that the absolute accuracy, drift, and noise of the oxygen measurement will remain the same for all ranges (see Specifications in Preface).

ALARM Mode

ALARM Mode is not self-resetting. Operator must press ACK to bring relays back to their no-alarm state. Used when immediate operator action is required.

NOTE:

Operator Can Bypass Alarm Relays

When relays are set to ALARM Mode (Section 3-6a on page 3-16) and an alarm condition has occurred, pressing the ACK key will turn off the relay switch, whether the oxygen level is out of range or not. If you do not want an operator to be able to bypass the relay switches in this way, set the instrument to ON/OFF -CONTROL Mode.

ON/OFF-Controller Mode

ON/OFF-CONTROLLER Mode is selfresetting. Pressing ACK has no effect on relay coils. Used when automated action is required.

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1-6 SPECIFICATIONS

a. Performance

Accuracy........................................ ±0.25% oxygen

Operating Range ........................... 0 to 25% oxygen (endpoints set by user)

Linearity ......................................... ±0.25% oxygen

Zero Stability.................................. ±0.25% oxygen/week at 25°C

Span Stability................................. ±0.25% oxygen/24 hours at 25°C

Noise ............................................. ±0.25% oxygen

Response Time ............................. 90% of reading in 20 seconds at 25°C

Temperature Effects

32 to 110°F (0 to 44°C) ......... ±6% reading

60 to 90°F (15 to 32°C) ......... ±3% reading

other 30°F (16°C) ranges ...... +4% reading

Model 7003M

(with constant sample temperature after sensor zero offset correction)

b. Physical

Mounting

Standard ................................ Panel Mount

Optional ................................. Wall Mount, Pipe Mount

Dimensions.................................... 5.7 x 5.7 x 7.6 inches (14 x 14 x 19 cm) HxWxD

Weight ........................................... Approximately 3.0 pounds (1.36 kg)

Enclosure....................................... ABS Plastic, Black, NEMA Type 4X, IP65

Ambient Humidity .......................... 95% relative humidity, non-condensing (maximum)

Ambient Temperature.................... 14 to 122°F (-10 to 50°C)

Sensor Cable................................. 2 twisted pairs, specified length up to 1000 feet (305 m) maximum

Power Cable.................................. 3 conductor, Type SJT, 18 AWG minimum

Connection Conduit

Power..................................... 1/2 inch

Sensor ................................... 3/4 inch

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

c. Electrical

Power Requirements..................... 115/230 VAC ±10%, 50/60 Hz ±3 Hz

Display........................................... 3-1/2 digit liquid crystal (LCD)

Signal Output................................. Isolated 4 to 20 or 0 to 20 mA (selectable)

Alarm Relay Contacts.................... Two Form C Relays

Recorder Output............................ Isolated 4 to 20 mA

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600 ohms maximum load

SPDT, resistive load, independently adjustable Deadband adjustable over full range Alarm Relay Contacts Ratings General Purpose (Ordinary) Locations: 115 VAC, 3.0 A (resistive), 230 VAC, 1.5 A resistive Class I, Division 2 Locations: CSA: 120 VAC, 3.0 A (non-inductive) 240 VAC, 1.5 A (non-inductive). FM: 28 VDC (resistive) (Ci = 0, Li = 0) Groups A&B: 150 mA Group C: 400 mA Group D: 540 mA

d. Sensors

Types............................................. Rechargeable and Disposable

Process Connections .................... Refer to flow chamber (if supplied)

Sample Pressure........................... 0 to 50 psig (0 to 345 kPa)

Sample Temperature..................... 32 to 110°F (0 to 44°C)

Ambient Temperature.................... 32 to 110°F (0 to 44°C)

Ambient Humidity .......................... 95% relative humidity, non-condensing (maximum)

Also refer to instructions supplied with sensor.

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1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

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June 2002

SECTION 2

INSTALLATION

2-1 UNPACKING

Carefully examine the shipping carton and contents for signs of damage. Immediately notify the shipping carrier if the carton or contents is damaged. Retain the carton and packing material until all components associated with the Model 7003M Percent Oxygen Analyzer are operational.

2-2 STORAGE

The sensors and analyzer unit may be shipped together or separately. The sensors are shipped assembly and charged, ready for use.

If rechargeable sensors are stored longer than six months, they may need to be recharged or rejuvenated if performance is marginal. Disposable sensors are not rechargeable.

Refer to documentation supplied with sensors for more information.

2-3 ANALYZER INSTALLATION

The Model 7003M Percent Oxygen Analyzer is designed to meet NEMA Type 4X (CSA enclosure 4) requirements, provided that the cutouts in the bottom of the enclosure are fitted with approved conduit fittings or are properly sealed by the user with Hoffman plugs (PN A-S050) or equivalent.

The Model 7003M is supplied with the Panel Mounting Kit PN 652527 as standard. Optional Wall Mount Kit PN 652539 and Pipe Mount Kit PN 652529 are available. Refer to the Outline and Mounting drawings provided in the rear of this manual.

2-4 SENSOR INSTALLATION

NOTE:

Refer to Figure 2-1 Sensor Ordering Matrix on page 2-2, and verify that the sensor to be used corresponds with the application. If an incorrect sensor is used, calibration may be impossible or incorrect. If a different type of sensor is to be used, the rocker switch (SW1) on the Signal Board may have to be changed (see Section 2-4a below).

Install the sensor in an area where temperature is relatively constant, taking care to avoid changes in exposure to sunlight or due to sudden drafts. A room-temperature environment is preferable. The flow chamber/sensor kit contains detailed mounting and sample flow information. Add distilled or deionized water to the sensor to the maximum level indication on the sensor reservoir. Let sensor stand for approximately 15 minutes and check for leaks around the base of the reservoir, and at the seams and corners. If a leak is found, contact the factory before proceeding. Drain the sensor.

a. Analyzer/Sensor Jumper Configuration

The Model 7003M is configured to match the type of sensor ordered with the analyzer. If the Signal Board or Sensor is repaired or replaced, verify rocker switch SW1 on the Signal Board is properly set.

Rechargeable Sensor: Close positions 1, 4, and 5

Disposable Sensor: Close positions 2, 4, and 6

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Model 7003M

4000 Rechargeable Sensor 5000 Disposable Sensor

1 Polypropylene 2 Ryton (rechargeable only) 9 Special (consult factory)

1 Submersion 2 In-Line Flow 3 Fast Response (rechargeable only) 9 Special (consult factory)

4 0 0 0 3

Position →

Positions 1 through 4 = Sensor Type Position 5 = Material of Construction (Sensor and Flow Assembly) Position 6 = Flow Assembly Configuration

Example 400013 is a Rechargeable sensor, constructed of polypropylene, mounted in a Fast-Response Flow Chamber Assembly.

1234

Figure 2-1. Sensor Ordering Matrix

2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

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2-5 ELECTRICAL CONNECTIONS

Observe all precautions stated in this manual and in the drawings provided at the back of this manual before installation.

All electrical connections to the analyzer are made on the Power Supply Board connection panel (see Figure 2-2 below and drawing

652683), which is accessed by removing the rear cover.

WARNING

ELECTRICAL SHOCK HAZARD

Do not operate without rear cover secured. Servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel.

For safety and proper performance this instrument must be connected to a properly grounded three-wire source of power.

Electrical installation must be made in accordance with the National Electrical Code (ANSI/NFPA-70) and/or any applicable national or local codes.

WARNING

ENCLOSURE INTEGRITY

Unused cable conduit entries must be securely sealed by non-flammable closures to provide enclosure integrity in compliance with personnel safety and environmental protection requirements. For watertight installation conforming to the requirements of NEMA Type 4X, use Hoffman plugs (PN A-S050) or equivalent to seal any unused openings.

Provide three separate 1/2 inch conduits as follows:

•

Power cable

•

Sensor cable

•

Alarm cables

1 +12V 2 -12V 1 ANODE 2 TEMP SENSE 3 NC 4 NC 5 EPOL 6 GND 7 Tx 8 Rx 9 RET 1 COM 2 NC 3 NO 4 COM 5 NC 6 NO 7 ISO GND 8 ISO CUR9 ISO CUR+

ALARM CONTACT RATING: 3A 120 VAC

1.5A 240 VAC 3A 30 VDC

AC POWER

AL 1

AL 2

HOT NEUT GND

L1 L2

FUSE RATING: 115V: 1/4A 250V 230V: 1/8A 250V

Figure 2-2. Model 7003M Rear Panel Connections

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a. Sensor Cable

The sensor cable used with the Model 7003M may be of any length up to a maximum of 1000 feet (305 m). (See Table 2-1 below.)

The signal cable should be routed through a conduit (customer-supplied) in permanent installations or in cases where the sensor is located more than a few feet from the control unit. (See Table 2-2 below.)

Model 7003M

Connect Sensor Cable

1. Ensure that power is disconnected and remove rear cover.

2. Install the conduit or cable clamp in the left opening in the bottom rear of the case.

3. Install the sensor cable in the instrument through the cable clamp and tighten the nut on the plug to create a seal around the cable.

NOTE:

In humid environments, temperature changes can cause moisture to condense in the conduit, resulting in signal noise and corrosion. To minimize the effect of condensation, put desiccant (available locally) inside the conduit before sealing it.

CABLE PART

NUMBER

191748 10 Feet (3.1 m) 193265SPECL

Table 2-1. Sensor Cables

If conduit used:

1/2 inch NPT female connection on bottom of control unit. (Conduit customer-supplied.

If no conduit used:

Use cable connector assembly (PN

856831) to provide watertight seal. Assembly includes: Aluminum inner sealing grommet for connector compression nut.

Table 2-2. Analyzer Cable

Connections

LENGTH

Any specified length up to 1000 Feet (305 m)

4. Refer to Figure 2-2 on page 2-3. Using a flat-blade screwdriver, connect the wires of the sensor cable to the TB2-1, TB2-2, TB2-5 and TB26 on the rear panel of the analyzer.

5. Replace the rear cover if no other connections are to be made. Do not overtighten the cover retaining screws to avoid stripping the threads in the plastic case.

b. Power Connections

Electrical power is supplied to the analyzer via a customer-supplied three conductor cable, type SJT, minimum 18 AWG. Refer to the installation drawing in the rear of this manual.

Jumpers and Fuses

To verify the jumper location for the specified power (115 or 230 VAC) or if the analyzer is to be connected to a different power source, refer to Figure 2-3 on page 2-5and set jumpers and fuse as follows:

WARNING

ELECTRICAL SHOCK HAZARD

Disconnect power to analyzer before continuing.

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WARNING

1. Remove the rear cover from the analyzer.

2. Remove Power Supply Board.

3. Verify and/or set Jumpers E1, E2, E3, and E4 per Figure 2-3 below.

4. Verify that fuse (F1) is correct for power.

5. Re-install Power Supply Board.

6. Replace the rear cover if no other connections are to be made. Do not overtighten the cover retaining screws to avoid stripping the threads in the plastic case.

Conduit Connections

Route the power cable through conduit and into the central opening in the bottom of the case. The inlet hole is sized for standard 1/2 inch conduit fittings.

ENCLOSURE NOT GROUNDED

The non-metallic enclosure does not provide grounding between conduit connections. Use grounding-type bushing and jumper wires.

Connect Power Cable

Connect power wiring to the compression type connectors on the rear panel (Figure 2-2 on page 2-3) as follows:

1. Loosen the connector screw.

2. Strip insulation back approximately 1/4 inch (6.35 mm), twist stranded wires together. DO NOT tin braid wire or the connection can work loose.

3. Insert wire into connector about 1/4 inch (6.25 mm), ensuring that wires do not touch any other wire or connector.

4. Tighten screw.

115 VAC

Jumpers: E1 - E2 E3 - E4 Fuse: 1/4 Amp

115 VAC

Jumpers: E2 - E4 Fuse: 1/8 Amp

Power Supply Board

F1 E3 E4 E2 E1

1/4 AMP 115 VAC

F1 E3 E4 E2 E1

1/8 AMP 230 VAC

Figure 2-3. Power Jumpers and Fuses

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Model 7003M

CAUTION

TOTAL OUTPUT RESISTANCE

Total resistance of all output devices and associated interconnection cable must not exceed 600 ohms.

c. Current Output Connections

Refer to Figure 2-4 on page 2-7. Isolated current output (0 to 20 or 4 to 20 mA) is standard on the Model 7003M. To convert from current output to voltage output, see Section 2-5d below.

1. Disconnect power to the analyzer. Remove rear cover.

2. Connect the shielded recorder cable leads to the rear panel of the analyzer (Figure 2-2 on page 2-3):

TB3-7 has no connection TB3-8 negative (-) TB3-9 positive (+)

3. Connect the other end of the output cable to terminals of the output device. Ensure that polarity is correct. Connect the shield to a suitable ground point.

NOTE:

Current output terminals are not grounded. Ground the current loop at some point within the circuit to minimize noise or other undesirable interactions.

4. Replace the rear cover. Do not overtighten cover retaining screws, to avoid stripping the threads in the plastic case.

5. To connect recorder(s), see Figure 2-4 on page 2-7.

d. Voltage Output Connections

Refer to Figure 2-4 on page 2-7. To convert the voltage output to current output see Section 0 above.

To monitor the signal output with a voltage recorder or other voltage device, the standard current output must be converted into a voltage by connecting a resistor in parallel with the output device as follows:

1. Determine the resistor value (R) required:

ohms = (fullscale voltage,

volts)/(0.02 amps)

2. Disconnect power; remove the rear cover.

3. Connect resistor (1/4 watt or greater) of value R between TB3-8 and TB3-9 (Figure 2-4 on page 2-7).

4. Connect leads of a shielded recorder cable to the rear panel of the analyzer (Figure 2-2 on page 2-3):

TB3-7 has no connection TB3-8 negative (-) TB3-9 positive (+)

5. Connect other end of output cable to terminals of output device. Ensure that polarity is correct.

6. Replace the rear cover. Do not overtighten cover retaining screws, to avoid stripping the threads in the plastic case.

7. For the low end point to be 0 volts, set the current output range to 0 to 20mA when setting up the instrument (Section 3-5b on page 3-13).

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Model 7003M

TB3

RECORDER

S - +

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ONE RECORDER

NEG (-)

POS (+)

NEG (-)

POS (+)

RECORDER

S - +

RECORDER

S - +

MULTIPLE

RECORDERS

Figure 2-4. Current Output Connections

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Model 7003M

2-6 RELAY CONTACTS FOR ALARMS OR

ON/OFF-CONTROLS

NOTE:

Whenever "Alarm" is used, it refers to either alarm or ON/OFF Control, depending on how the relays are connected and configured by the customer.

Ratings

Two sets of alarm relay contacts are provided for actuation of customersupplied alarm and/or ON/OFF-Control functions. (see Section 1-6 specifications on page 1-4).

Power Failure

Removal of AC power from the analyzer, as in a power failure, removes power from both relay coils. The Model 7003M should operate on a different AC power source than the Alarm relay contacts.

Connecting Devices to Relay Contacts

WARNING

RELAY CONTACTS

Relay contacts wired to separate power source must be disconnected before servicing.

Connect alarm or ON/OFF-Control devices to the relay contacts as follows:

1. Disconnect power; remove rear cover of analyzer.

2. Connect leads from the external alarm or ON/OFF Control system (see Figure 2-2 on page 2-3).

TB3-1 Alarm 1 Com TB3-2 Alarm 1 NC TB3-3 Alarm 1 NO TB3-4 Alarm 2 Com TB3-5 Alarm 2 NC TB3-6 Alarm 2 NO

Radio Frequency Interference (RFI)

If alarm contacts are connected to any device that causes radio frequency interference (RFI), an arc suppressor (PN

858728) should be used to minimize RFI.

3. Connect other end of output cable to terminals of alarm device.

4. Replace the rear cover. Do not overtighten cover retaining screws, to avoid stripping the threads in the plastic case.

NOTE:

For installation in a Class I, Division 2 location, refer to the Specifications in the Preface section, and the approval label on the analyzer for Factory Mutual limitations on contact ratings.

2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

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SECTION 3

OPERATION

3-1 OVERVIEW

It is recommended that the operator read the entire manual through before first operating the instrument.

The operator can generally operate the Model 7003M using the flow chart in Figure 3-2 on page 3-2 after the display symbols and modes of operation are understood.

3-2 KEYPAD OPERATION

During each particular keystroke sequence, the analyzer will recognize only certain keys. If an unrecognized key is pressed, the instrument will either not respond or will display "SrY" ("Sorry") and return to RUN Mode.

Generally, to escape from any routine, press ENTER repeatedly until the instrument returns to the RUN Mode and the oxygen concentration is displayed.

Changing Parameters With The Keypad

All operation parameters are set with the keypad. When the instrument is waiting for operator input, the display will flash a digit. At this point, if the number itself can be changed, the operator can generally increase the number (UP arrow) or decrease it (DOWN arrow) at this time. An exception is when the operator is restricted to pre-selected choices (e.g., output current ranges, see Section 3-5b on page 3-13).

When changing a value, an arrow key can be pressed for a moment, and the display will change by one digit. If it is held down, the display will change, slowly at first, then rapidly.

If the display has a digit flashing and will not change, check the range of that parameter. For example, an alarm setpoint cannot be set higher than 25%.

When the number desired is displayed, press ENTER. The Model 7003M will accept that number and continue with the next step of that routine.

Rosemount Analytical

ALARM1

ALARM2

%O2

MODEL 7003M

DISPLAY ACK

PERCENT OXYGEN

Figure 3-1. Model 7003M Front Panel Controls and Indicators

Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-1

ALARM1ALARM

ANALYZER

CAL ENTER

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Model 7003M

RUN MODE

Display Oxygen Temperature

SETUP MODE

CAL + ENTER

ENTER SECURITY

CODE

Set New Security Code

ENTER ACK

Select

ACK

0-20 or 4-20mA

ENTER

Set Concentration for Minimum Output Current

ENTER

ZERO GAS

ENTER

(0 or 4mA)

Set Concentration for Maximum Output Current

(20mA)

FLOW

Set Residual Current Offset

ALARM MODE

ALARM1*

ENTER SECURITY

CODE

ENTER

DISPLAY ACK

Disable Alarm

ALARM 1*

Toggle

ON/OFF

Change "ON" Setpoint

Change "OFF" Setpoint

Acknowledge Alarm

CALIB. MODE

CAL

ENTER SECURITY

CODE

ENTER

Return to

RUN Mode

PRESSURE

COMPENSATION

ROUTINE

CAL

ENTER

Reveal Security Code

HOLD MODE

ENTER SECURITY

Set Span Concentration

DIAGNOSTICS

DISPLAY + ACK

Set Sample Pressure

Set Span Gas Pressure

ENTER

CODE

ENTER

Return to

RUN Mode

MODE

DISPLAY

Select Displayed Parameter

ALARM 1*

Toggle

ON/OFF

Change Current Output

Return to

RUN Mode

Return to

RUN Mode

Return to

RUN Mode

Return to

RUN Mode

*Press ALARM 2 to set Alarm 2.

Figure 3-2. Model 7003M Operation Flow Diagram

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a. Single and Double Keystroke

Most procedures involve a sequence of single keystrokes by which the operator

KEY FUNCTION HOW TO USE IT

ACK Acknowledges an alarm condition Press once to silence alarms

DISPLAY

ARROW keys Increase/Decrease displayed value

CAL Access CALIBRATION mode

ENTER End command sequence

ALARM1 Access ALARM 1 mode

ALARM2 Access ALARM 2 mode

CAL + ENTER Access SETUP mode

UP + DOWN ARROW Access HOLD mode.

DISPLAY + ACK Access DIAGNOSTICS mode

DISPLAY + ACK Access security ID code

Switch between %O2 and °C

Press to display °C; press again to display O2. Output signals are not affected. Press once to change value by one digit. Hold key down to change value quicker. Press to calibrate. (If security is enabled, prompts for ID code first) Press to enter value or to end a command sequence Press to check, set or disable Alarm 1 or ON/OFFControl relays Press to check, set or disable Alarm 2 or ON/OFFControl relays From RUN mode, press CAL and ENTER keys simultaneously. From RUN mode, press UP ARROW and DOWN ARROW keys simultaneously. From HOLD mode, press DISPLAY and ACK keys simultaneously. From RUN mode, press DISPLAY and ACK keys simultaneously.

presses one key at a time. Some of the more frequently used single-key commands are listed in Table 3-1 below.

Table 3-1. Key Functions

INDICATOR CARET/STATUS DESCRIPTION

%O2 Caret ON Oxygen percentage displayed

°C ALARM1,2 Caret OFF Normal condition ALARM1,2 Caret blinking Alarm condition

- Caret ON

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 3-3

Caret ON

Sensor temperature displayed, °C

Displays current output in mA (DIAGNOSTICS mode only)

Table 3-2. Display Indicators

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b. Display Prompts

The Model 7003M prompts the operator for inputs and also indicates the function

CODE DEFINITION

id enter security code prompt

no invalid security code entered - access denied

YES access granted or security code entered is correct

Table 3-3. Security Access Prompts and Responses

CODE DEFINITION

A-1 setpoints for Alarm 1 - ALARM function A-2 setpoints for Alarm 2 - ALARM function C-1 setpoints for Alarm 1 - ON/OFF - Controller function C-2 setpoints for Alarm 2 - ON/OFF - Controller function

On value in which to initiate an Alarm Action (On-setpoint)

OFF value in which to terminate an Alarm Action (Off-setpoint)

dis Alarm is now disabled

Table 3-4. Alarm Settings Prompts and Responses

in progress. For example, when entering the calibration mode, the prompt "CAL" is displayed for one second after the CAL key is pressed. Display acronyms are listed in Table 3-3 through Table 3-9.

CODE DEFINITION

CAL initiate a span calibration

PPr enter process pressure value

CPr enter calibration pressure value

GAS Initiate a zero offset calibration (gas)

Table 3-5. Calibration Prompts and Responses

CODE DEFINITION

Set enter system setup mode 4-0 define the current output as 4-20 or 0-20 mA

CLo % concentration that 0/4 mA represents (calibration low)

CHi % concentration that 20 mA represents (calibration high)

Table 3-6. System Setup Prompts and Responses

3-4 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

CODE DEFINITION

A-1 toggle ON/OFF check of relay coil for Alarm 1

A-2 toggle ON/OFF check of relay coil for Alarm 2 D-2 performing non-intrusive test Internal RAM (16#00#..16#FF#) D-3 performing non-intrusive test on Internal RAM (16#4000#..16#5FFF) D-4 performing non-intrusive test on EEPROM (16#B600#..16#B7FF#) D-5 performing non-intrusive test on PROM (16#C000#..16#FFFF#)

F-2 failed D-2 test

F-3 failed D-3 test

F-4 failed D-4 test

F-5 failed D-5 test

hld entering system Hold

OFF alarm relay is de-energized (normally-closed)

On alarm relay is energized (normally-open) tSt entering on-line test diagnostics mode

CODE DEFINITION

caret lit displayed

O2 sensor membrane voltage from ADC

Temp sensor thermistor voltage from DC

minus sign milliamps sent to current output

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Table 3-7. System Hold and Diagnostics Codes

Table 3-8. Data Displayed in DIAGNOSTICS Mode

CODE DEFINITION

Sry invalid keypad function (Sorry)

run current function completed - entering RUN Mode

Table 3-9. Miscellaneous Prompts and Responses

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c. Error Messages

If an error condition occurs, E-# (non-fatal error) or F-# (fatal error) will flash on the

CODE DEFINITION

F-1 Invalid PROM (16#C000#..16#FFFF#) checksum detected F-2 Internal RAM (16#00#..16#FF#) failed testing F-3 External RAM (16#4000#..16#5FFF) failed testing F-4 EEPROM (16#B600#.. 16#B7FF#) bulk erase failure F-5 Signal Board not connected

F-6 thru F-9 EEPROM write failure

Table 3-10. Power ON, Reset Diagnostics Errors (Fatal Errors

CODE DEFINITION

E-1 5 volts power supply above 5.5 V E-2 5 volts power supply below 4.5 V E-3 12 volts power supply above 13.2 V E-4 12 volts power supply below 10.8 V E-5 sensor output too low for calibration E-6 sensor missing E-8 E-9

sample temperature is below 1°C sample temperature is above 44°C

display. Table 3-10 through Table 3-13 list error codes and corrective actions. Pressing "ACK" or "ENTER" will acknowledge any alarm and the error message will disappear.

Table 3-11. RUN Mode Errors (Non-Fatal Errors

CODE DEFINITION

Ahi excessive sensor signal

CODE DEFINITION

COP Computer Operating Properly error (error detected)

iot Invalid Op code Trap (internal computer command is invalid)

E-0 power interruption occurred

sample temperature is above 50°C sample temperature is below 0°C

Table 3-12. Signal Board Errors

Table 3-13. Microprocessor Errors That Reset The System

3-6 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

d. Automatic Return to RUN Mode

If no keys are pressed for five minutes, the instrument will automatically return to the RUN Mode, except when in Zero Offset, HOLD, or DIAGNOSTICS Modes.

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After the security code is entered, the operator can change any instrument setting and can go back and forth to the RUN Mode without having to enter the code again.

CAUTION

OXYGEN WILL NOT BE MONITORED

The instrument will remain in HOLD or DIAGNOSTICS Modes until the operator returns it to the RUN Mode or other operation.

e. Preventing Unauthorized Access

The Model 7003M is equipped with a security feature to prevent unauthorized tampering with the instrument settings. The instrument is shipped from the factory with the security feature disabled. It can be enabled or disabled at any time.

Security access is not required to:

• Display sensor data

• Acknowledge alarms

• Reveal security code

Security access is required to:

If security is enabled, and the instrument is left in the RUN Mode for five minutes, security will automatically be re-activated. Within this five minute period, anyone can access the functions without re-entering the security code.

f. Sensor Equilibrium

When a new sensor is installed, power up the instrument and let the sensor stabilize for about 5 hours before calibrating it.

If the oxygen sensor is calibrated at a relatively high oxygen concentration, such as with ambient air (typically 20.95%) and then is exposed to a low oxygen level, a longer equilibrium time period may be required for the sensor to equilibrate. This time period depends on the monitoring concentration level and how long the sensor was operated at the higher level.

• Calibrate with span gas

• Access options and diagnostics

• Change operation parameters

• Enable or disable alarms and

ON/OFF-Control

• Disable or change the security code

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3-3 START-UP

Before proceeding, the operator should be familiar with the keypad and indicators (Section 3-2 on page 3-1).

Operational checks and adjustments are not normally required, provided that the sensor, inter-connection cable and analyzer have been properly installed. The analyzer continually performs self-checking routines during operation.

Calibration with ambient air is recommended after start-up and at regular intervals (see Section 4-2 on page 4-1)

The following sections provide instructions for initial start-up and subsequent standardization of the analyzer.

a. Initial Power-Up

1. Ensure that the proper sensor and sensor cable are connected to the analyzer.

2. Apply power to the analyzer.

The following internal tests are performed:

ROM "Checksum" test EEPROM Read/write test

3. If an error code flashes, refer to the error code lists in Table 3-10 through Table 3-13. Press ACK to continue with the startup procedure.

After internal tests are passed, the software version is displayed for a few seconds, and the analyzer goes directly into RUN mode. "RUN" is briefly displayed, then current oxygen level.

Error codes E-0 (power failure) and E-5 (not calibrated) typically occur upon power-up.

4. Monitor the oxygen output or display until the level stabilizes (typically 5 hours). The alarms and current output levels can be set immediately if desired.

5. Once the sensor has stabilized, the analyzer is operational and is ready for subsequent operations. Refer to Table 3-14 below for the default settings present upon power-up.

RAM Read/write test

Mode: Alarm

Alarm 1

Range

Current Output Range 4-20 mA Security Disabled

Pressure

Residual Zero Offset 0 Calibration Status Not Calibrated

3-8 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

State: Disabled Setpoints: On: 0.0 Off: 0.1% Mode: Alarm State: DisabledAlarm 2 Setpoints: On: 0.0 Off: 0.1% 0% of scale: 0% Oxygen 100% of scale: 25% Oxygen

Calibration: 76.0 cm Hg Process: 76.0 cm Hg

Table 3-14. Default Settings at Power-Up

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b. System Restart

The Model 7003M will attempt to restart itself in the event of a power interruption, power surge or other outside interference to microprocessor operation (Section 3-3c below).

The analyzer can also be manually restarted if the RAM or EEPROM becomes corrupted (Section 3-3d below).

c. Automatic Restart - Due to Power

Failure

If a power failure or other event occurs that affects operation of the microprocessor the system will attempt to re-start itself. If it is successful, the instrument will continue to operate normally, except that the appropriate error code will be displayed until the ACK button in pressed. See Section 5-3c on page 5-2 for circuit description.

d. Manual Restart

1. Turn power to analyzer OFF.

2. Wait 30 seconds, and turn the power to the analyzer ON.

3. While the software revision is being displayed and the self-tests are being performed, press DISPLAY and ACK simultaneously.

"dYn" is displayed.

4. Press ENTER to clear the RAM and EEPROM.

The display will go blank, then continue with the SETUP routine.

Continue with Section 3-5a on page 3-13, step 2.

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3-4 RUN MODE

Refer to Figure 3-2 on page 3-2 and Table 3-15 below. The RUN mode is the normal mode of operation, from which the operator can:

KEY DISPLAY WHAT HAPPENS

DISPLAY Number change Toggles between O2 reading and temperature ACK Clears message Acknowledges Alarms ALARM 1 "A-1" then ON To Alarm 1 SETUP mode ALARM 2 "A-2" then ON To Alarm 2 SETUP mode UP ARROW "SrY" "run" Stays in RUN mode DOWN ARROW "SrY" "run" Stays in RUN mode CAL "CAL" then ON To CALIBRATION mode ENTER "SrY" "run" Stays in RUN mode CAL + ENTER "SEt" then ON Moves to SETUP mode UP + DOWN "hLd" then ON Moves to HOLD mode DISPLAY + ACK "123" Shows the security code

• Display oxygen concentration and sensor temperature

• Acknowledge alarms

• Display security code

• Access other modes

Table 3-15. RUN Mode Key Functions

a. Display Oxygen Concentration/Sensor

Temperature

Press DISPLAY once to display sensor temperature. Press DISPLAY again to display oxygen concentration.

b. Acknowledge Alarms

If an alarm setpoint has been reached, "A1" or "A-2" will flash with a concentration value. Acknowledging the alarm will stop the flashing display and turn off the relay switch.

To Acknowledge Alarm - Press ACK key. If relays are configured as ON/OFF controllers, pressing the ACK key has no effect.

3-10 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

c. Access Other Modes

The following lists which key(s) to press to access various modes:

SETUP = CAL+ENTER ALARM = ALARM1 (or ALARM2) CALIBRATION = CAL HOLD = UP and DOWN ARROWS DIAGNOSTICS = DISPLAY+ACK (from HOLD)

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3-5 SETUP MODE

Refer to Figure 3-3 on page 3-12 and Table 3-16 below. From the SET-UP mode the operator can:

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK "<4>-0" / "4-<0> Selects 4-20 or 0-20 mA operation ALARM 1 Nothing Nothing ALARM 2 Nothing Nothing UP ARROW DOWN ARROW

10.8 →10.9

10.9 →10.8 CAL Nothing Nothing ENTER various to "run" Moves to the next step or goes to RUN mode

Table 3-16. SETUP Mode Key Functions

• Change security code

•

Set output current range (0-20mA or 420mA)

•

Set output concentration range endpoints

•

Adjust zero offset

Changes the number displayed Changes the number displayed

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SET-UP Mode

CAL ENTER

Model 7003M

Flashing

Flashing May not be displayed each time.

Flashing

ALARM1

ALARM2

%O2

SECURITY ACCESS ROUTINE

(see Figure 3-4)

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

%O2

Prompts for Security Code. If left at 000, code will be disabled. Use Arrow keys to set Security Code.

Select either 4-20mA or

ACK

0-20mA Output

ENTER

ALARM1

ALARM2

%O2

Prompts for low end output. (i.e., 0% O2 would be the low range

ENTER

representing O2 level of 0 or 4mA.

Flash for 2 seconds

(Hi range output selection)

Flash for 2 seconds

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

%O2

Prompts for zero offset

%O2

Set Span output level = 20mA

ENTER

Figure 3-3. SETUP Mode Flowchart

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a. Security Code

Refer to Figure 3-4 on page 3-14.

Reveal Current Security Code

From RUN mode, hold down DISPLAY and ACK keys simultaneously.

Change Current Security Code

1. From RUN mode, press CAL and Enter simultaneously.

2. SET, id are briefly displayed. Then "000" is displayed with the right digit flashing.

NOTE

If RUN and CAL are not press exactly at the same time, "SRY", or "RUN" will appear, and the analyzer will return to RUN mode.

3. If the security code has been disabled, skip to step 4. Use the ARROW keys to enter the current security code, then press ENTER.

1. Press ACK until the desired range is flashing, press ENTER.

2. Continue with the next SET-UP routine, or hold ENTER key to return instrument to RUN mode.

c. Range Endpoint Adjustments

The oxygen values corresponding to minimum and maximum output current must be set. Default is 0% for 0 or 4mA and 25% for 20mA. Endpoints must be within the range of the instrument and must be at least 1% oxygen apart.

Set Oxygen Low Concentration Endpoint

Following the last procedure, "CLo" is displayed briefly, followed by the oxygen concentration last stored to correspond to minimum output current.

NOTE

If "CLo" is set to a value greater than "CHi", "CHi" will be automatically reset to a value 1% greater than "CLo".

4. If the correct code is entered, YES, SET, id will be displayed briefly, the code will flash. If the incorrect code is entered the analyzer will return to RUN mode.

5. Use the ARROW keys to set the new security code (or "000" to disable), press enter.

6. Continue with the next set-up routine, or hold down ENTER until "run" appears (the instrument is back in RUN mode).

b. Current Output Range - 0-20mA or 4-

20mA

Following the last procedure, "4-0" is displayed with either digit flashing. "4" indicated 4-20mA (default), and "0" indicates 0-20mA.

Use the ARROW keys to set the low oxygen concentration (0 to 24%), press ENTER.

"CHi" is displayed briefly, followed by the latest oxygen concentration stored corresponding to maximum output current.

Set Oxygen High Concentration Endpoint

"CHi" cannot be set to a value equal to or less than "CLo".

Use the ARROW keys to set the high oxygen concentration (1 to 25%), press ENTER.

Continue with next SET-UP routine or hold ENTER to return to RUN mode.

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Model 7003M

RUN

SET-UP Mode

CAL ENTER

ALARM CAL

WAS SECURITY ID

ENTERED <5 MIN.

AGO

ENTER ID

ENTER

CORRECT

HOLD Mode

YES

OPERATOR GIVEN

ACCESS TO SE-

LECTED MODE

YES

ACCESS DENIED

Returns to

RUN mode

Figure 3-4. Security Access Routine Flowchart

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d. Zero Offset Adjustment

Following the last procedure, the current zero offset value will be flashing.

NOTE

When flowing zero gas over the sensor, ensure that there are no leaks and the gas actually has zero oxygen concentration. Otherwise, significant errors will result. Zero offset adjustment is generally not required. Errors are more often due to incorrect zero gas oxygen concentration than residual current of the oxygen sensor.

The zero offset adjustment allows the operator to compensate for any residual sensor current. Adjustment range is 0-5% equivalent oxygen.

Sensor Current = Current from Oxygen + Residual Current

NOTE

Adjusting the zero offset affects the output of the Model 7003M. Therefore, if the zero offset is changed, the system must be re-calibrated with span gas.

Zero Offset Is Not To Be Changed

Press ENTER to return analyzer to RUN mode, and skip the remainder of this procedure.

Zero Offset Is To Be Removed

1. Press the UP ARROW until the maximum value is displayed.

2. Press ENTER and re-calibrate with span gas per Section 4-2b on page 4-

Zero Offset To Be Adjusted

1. Expose the sensor to 100% oxygenfree nitrogen or other inert gas and allow the sensor signal to stabilize (25 hours depending on sample conditions).

2. Use the DOWN ARROW to bring the displayed value to zero (for maximum offset).

3. Press ENTER to return to RUN mode.

4. Re-calibrate with span gas per Section 4-2b on page 4-1.

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3-6 ALARM MODE VS. ON/OFF-CONTROL

MODE

Refer to Figure 3-5 on page 3-17 and Table 3-17 below. From the ALARM or ON/OFFControl Mode, the operator can:

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK "dIS" Disables alarms ALARM 1 "C-1" / "A-1" Toggles between alarm and controller mode ALARM 2 "C-2" / "A-2" Toggles between alarm and controller mode UP ARROW DOWN ARROW CAL Nothing Nothing ENTER "OFF" / "run" Moves to the "OFF" setpoint step or goes back to RUN mode

a. Relay Configured as Alarm

Relays are configured as alarms (ALARM Mode) when immediate operator action is required.

When alarms are selected, "A-1" and "A2" are displayed in the ALARM mode setup procedure.

10.8 →10.9

10.9 →10.8

Table 3-17. ALARM Mode Key Functions

• Set alarm ON and OFF setpoints.

• Select alarm or ON/OFF-Control function

for relays

• Disable alarm(s)

Changes alarm setpoint Changes alarm setpoint

b. Relay Configured as ON/OFF-

Controller

Relays are configured as ON/OFFControllers (ON/OFF-Controller mode) when a non-critical, non-hazardous automated action is desired, or when it is important that the relay output not be bypassed by the operator.

When an alarm condition occurs, the caret blinks, the relay activates, and the display flashes. Press the ACK key to acknowledge the alarm, de-energize the relay coil and stop the alarm actions.

3-16 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

When ON/OFF-Controllers are selected, "C-1" and/or "C-2" is displayed in the ALARM mode set-up procedure.

When an ON/OFF-Controller alarm condition occurs, Alarm 1 or 2 caret blinks and the relay coil is energized. However, the display does not flash, and the ACK key is inactive. Alarm conditions are automatically reset when the sensor indicates that an alarm condition no longer exists.

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ALARM/CONTROLLER MODE

To Disable Alarm

Indicates Alarm is disabled

Flashes Alarm Configuration

ALARM1

ALARM2

Flashing

ALARM1

ALARM2

Prompts "ON" Setpoint

Displays "ON" Setpoint

ACK

%O2

ALARM

ALARM1

ALARM2

Note: Alarms are disabled when instrument is received. Alarm 2 uses identical sequence.

%O2

SECURITY ACCESS ROUTINE

see Figure 3-4

ALARM1

ALARM2

%O2

ALARM1

ALARM2

ALARM1

ALARM2

%O2

ALARM1

ALARM2

%O2

STANDARD ALARM

Adjust Alarm ON Setpoint

ENTER

%O2

Flashes Control Configuration

ALARM

Change Relay configuration

ALARM1

ALARM2

%O2

ALARM1

ALARM2

ALARM1

ALARM2

%O2

Prompts for OFF Setpoint

%O2

Adjust Alarm OFF Setpoint

ENTER

ALARM1

ALARM2

New values/functions will not be stored until instrument returns to RUN mode with relay activated.

%O2

Figure 3-5. ALARM Mode Flowchart

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c. Relay Contacts

Relay contacts are listed in Table 3-18 below:

Model 7003M

RELAY POS

TERMINAL LOCATIONS

ALARM1 ALARM2

NO (Normally open) TB3-3 TB3-6 NC (Normally closed) TB3-2 TB3-5 COM (Common) TB3-1 TB3-4

Relay positions are with power removed.

Table 3-18. Alarm Relay Contact Positions/Terminal Locations

d. Fail Safe Operation

g. Setting Alarm and ON/OFF-Controller

The relays are setup to operated in "Fail Safe" configuration. In this configuration the relay coils are powered when the unit is NOT in an alarm condition. When an alarm condition occurs, power is removed from the relay coils.

Wherever "Alarm" is referred to in this section, the term "ON/OFF-Controller" can be substituted, unless specifically called out. Also, any reference to A1 or Alarm 1 also applies to Alarm 2, and to ON/OFF-

Controllers 1 and 2. If a power failure occurs, power will be removed from the relays and an alarm

h. Setting Alarm Setpoints

condition will be indicated to the device connected to the relays.

This procedure can be used to:

Relays

e. Relay Reset Upon Fatal Error

If a fatal error is detected, the unit will

•

Verify alarm relay setpoints

•

Change setpoints attempt to reset itself which will make both relays go into alarm mode. If the

•

Enable alarms microprocessor is able to continue its

operation, the relays will then be reset to

•

Disable alarms their normal operating position.

Perform the following procedure for each

f. Pressure Effects on Alarms

Alarm setpoint, as required. Figure 3-6

illustrates how relays are energized and If the sample pressure changes, the partial pressure of oxygen, and thus the

de-energized in High and Low Alarm

configurations. reading, will change and the alarm relays will not actuate at the same oxygen levels

as they were set when the interment was last calibrated. See Section 5-2a on page 5-1 for a more detailed description of pressure effects.

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i. Setting Alarm ON and OFF Levels

Refer to flowchart Figure 3-5 on page 3-

17.

From RUN mode, press ALARM 1.

A-1, YES, A-1 (or C-1), ON flash briefly; the alarm ON setpoint is displayed with the right digit blinking.

A-1 indicates relay 1 acts as an ALARM; C-1 indicates relay one acts as an ON/OFF-Control.

To change the relay action from

ALARM to ON/OFF Control function (or

vise versa) press ALARM 1. C-1 or A-1

will flash indicating a new mode.

To disable ALARM 1 - Press ACK.

"DIS" will flash briefly and return to RUN

mode.

To set the ON setpoint for ALARM 1 -

Use the ARROW keys, press ENTER.

OFF is flashed briefly, then the alarm OFF

setpoint is displayed with the right digit

flashing.

To set the OFF setpoint for ALARM 1 -

Use the ARROW keys, press ENTER.

The instrument displays "run" and returns

to RUN mode.

HIGH Alarm

set for 8.24% O

LOW Alarm

set for 8.10% O

Figure 3-6. Action of Alarm Relay ON and OFF Setpoints

8.24%

8.10%

8.24%

8.10%

ACTIVATES DE-ACTIVATES

ALARM ON

ACTIVATES DE-ACTIVATES

SETPOINT

OFF SETPOINT

OFF

TIME

ALARM ON

OFF

OFF SETPOINT

SETPOINT

TIME

DEADBAND

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3-20 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

SECTION 4

CALIBRATION AND ADJUSTMENTS

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4-1 FREQUENCY OF CALIBRATION

When a new sensor is installed, adjust the zero offset current (Section 3-5d on page 3-

15) and calibrate the instrument with span gas (4-2b on page 4-1. Span the instrument weekly at first and note the stability. Use this information to determine the regular calibration frequency required by this particular application.

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK Nothing Nothing ALARM 1 Nothing Nothing ALARM 2 Nothing Nothing UP ARROW DOWN ARROW

10.8 →10.9

10.9 →10.8 CAL "PPr" Moves to pressure compensation mode ENTER "run" Drops back to RUN mode

Table 4-1. CALIBRATION Mode Key Functions

a. Zero Calibration

Each oxygen sensor produces a constant residual electrical current in the absence of oxygen due to characteristics of the sensor. Typically this current is less that 0.1% apparent oxygen. It is different for each sensor, but will remain constant for the life of that sensor. The instrument can be zeroed by adjusting the residual current per Section 3-5d on page 3-15 After this procedure is performed once, the zero should not need adjusting again during the life of the sensor.

b. Span Calibration

4-2 CALIBRATION MODE

Refer to Figure 4-1 on page 4-3and Table 4-1 below. From the CALIBRATION Mode, the operator can:

• Calibrate with span gas

•

Enter sample and span gas pressures

Changes calibration factor Changes calibration factor

2. Press CAL to enter the CALIBRATION mode. Enter the security code if required.

3. CAL flashes and oxygen concentration is displayed with the right digit flashing. Output is held at last reading until returned to RUN mode.

4. Use the ARROW keys to set the instrument to the concentration of the calibration gas. See Table 4-2 on page 4-2 and Table 4-3 on page 4-2 if using ambient air as span gas.

1. Expose the sensor to ambient air and let the oxygen reading and sensor temperature stabilize.

We recommend using ambient air in calibration, re-

gardless of the range. Only when monitoring at 0 to

Rosemount Analytical Inc. A Division of Emerson Process Management Calibration and Adjustments 4-1

1% range, can the accuracy of the instrument be slightly improved by using a gas of lower concentration (e.g., 1%) for calibration. If bottled air is used, verify the oxygen concentration against National Bureau of Standards certified calibration gas. The true oxygen concentration in cylinders is often different from the concentration indicated on the cylinder label.

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5. Press ENTER to return to the RUN mode.

7. If the sample gas and the calibration gas are each at constant pressure, continue with Section 4-

6. If the ratio between the concentration value entered and

2c on page 4-4 and enter the

pressure of each. the sensor voltage is excessive, an error message will be flashed.

Oxygen 20.946% Nitrogen 78.084% Argon 0.934% CO2 0.033%

±0.002 ±0.004 ±0.004 ±0.001

Water Vapor 0.000% Other Gases Balance

760 mm Hg; 0% Relative Humidity

Table 4-2. Composition of Dry Atmospheric Air

GAS

15°C20°C25°C30°C

PERCENT COMPOSITION ( .002%) A@

Oxygen 20.641% 20.510% 20.338% 20.115% Water Vapor 1.683 2.307 3.126 4.187 Other Gases Balance Balance Balance Balance

760 mm Hg; 100% Relative Humidity

Table 4-3. Composition of Humid Atmospheric Air

CRC Handbook of Chemistry and Physics, R. Weast, ed., Chemical Rubber Co., Boca Raton, FL: CRC Press, 1987, p. F-

148.

Computed from data in CRC Handbook of Chemistry and Physics, p. D-190.

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CALIBRATION MODE

CAL

STANDARD CALIBRATION PROCEDURE

Example if using in Air

ALARM1

ALARM2

ALARM1

ALARM2

SECURITY ACCESS ROUTINE

see Figure 3-4

ALARM1

ALARM2

ALARM1

ALARM2

CURRENT %O

READING

%O2

ENTER

%O2

PRESSURE COMPENSATION SEQUENCE (i.e., CAL at atmospheric pressure, put sensor in different process pressure.

ENTER

ALARM1

ALARM2

ALARM1

ALARM2

%O2

Flash for 2 seconds

(Process Pressure)

%O2

ALARM1

ALARM2

%O2

Input Process Pressure in cm Hg

ENTER

ALARM1

ALARM2

ALARM1

ALARM2

%O2

Flash for 2 seconds

(Calibration Pressure)

%O2

Input Calibration Pressure in cm Hg

ENTER

ALARM1

ALARM2

%O2

Figure 4-1. CALIBRATION Mode and PRESSURE COMPENSATION Flowchart

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BAROMETRIC

PRESSURE

CM HG (IN. HG)

APPARENT O2 PARTIAL

PRESSURE

CM HG (DRY AIR)

CONCENTRATION WITH

NO PRESSURE CORRECTION

73 (28.7) 15.3 20.24% 74 (29.1) 15.5 20.52 75 (29.5) 15.7 20.80 76 (29.9) 15.8 20.95 77 (30.3) 16.1 21.36 78 (30.7) 16.3 21.63

Table 4-4. Barometric Pressure Effect on Apparent Oxygen Concentration

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK Nothing Nothing ALARM 1 Nothing Nothing ALARM 2 Nothing Nothing UP ARROW DOWN ARROW

10.8 →10.9

10.9 →10.8

Changes pressure value

Changes pressure value CAL Nothing Nothing ENTER "CPr" / "run" Moves to calibration pressure input or goes back to RUN mode

Table 4-5. PRESSURE COMPENSATION Mode Key Functions

c. Pressure Compensation - Correction

for Constant Pressure Differences

Refer to Figure 4-1 on page 4-3 and Table 4-5 above. If the sample and calibration gases are each at constant pressure, the following procedure should be used to correct for the pressure difference between them. However, the instrument does not monitor pressure and will not correct the output if either sample or calibration gas pressure changes. (See Section 5-2 on page 5-1).

1. From RUN mode, press CAL.

2. CAL, YES, CAL flash briefly, then the oxygen concentration is displayed with the right digit flashing.

3. Press CAL again.

Computed using 20.946% oxygen at 760 m.

4. PPr flashes, then previous sample pressure setting is displayed with right digit flashing (76.0 cm Hg is default).

5. Use ARROW keys to enter sample pressure.

6. Press ENTER to accept the value.

7. CPr flashes, then previous span gas pressure setting is displayed with right digit flashing (76.0 cm Hg is default).

8. Use the ARROW keys to enter pressure of the calibration gas to be used. If the sample and calibration gas will always be at the same pressure, set PPr and CPr at the same value.

9. Press ENTER to accept the value. Instrument returns to RUN mode.

4-4 Calibration and Adjustments Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

4-3 HOLD MODE

•

The last measured value is displayed

Refer to Figure 4-2 on page 4-7 and Table 4-6

•

below. In the HOLD mode:

•

All instrument functions are locked

•

All existing values are retained

•

The instrument stops responding to sensor signals

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK Nothing Nothing ALARM 1 Nothing Nothing ALARM 2 Nothing Nothing UP ARROW Nothing Nothing DOWN ARROW Nothing Nothing CAL Nothing Nothing ENTER "run" Drops back to RUN mode DISPLAY + ACK "d-4" "tSt" Moves to DIAGNOSTIC mode

The last output value remains at the isolated current output connections

•

Alarms and ON/OFF-Controllers are held in their last state

•

No keys are recognized except entry to the diagnostic routing.

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Table 4-6. HOLD Mode Key Functions

If the sensor cable must be disconnected, the instrument can be put in the HOLD mode, in which all existing signal levels and output current levels and output current levels are maintained. This may be useful to prevent disturbing an ON/OFF-control loop connected to the relay contacts.

1. Press the UP ARROW and DOWN ARROW at the same time to put the instrument on HOLD.

2. If the security is activated, enter the security identification (id) code and press ENTER to continue.

3. Hld, YES, flash briefly, then Hld flashes alternately with the last oxygen reading. The output signal will remain unchanged until the instrument returns to the RUN mode.

4. Press ENTER to return to the RUN mode, or continue with Section 4-4 Diagnostics Mode on page 4-8.

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Model 7003M

CARET

LIT

VALUE DISPLAYED

% Raw Sensor Voltage

°C

Thermistor Voltage 2.43 No

Current Output 17.43 Yes

Use ARROW keys to make adjustments.

Table 4-7. Caret Readings

TYPICAL

VALUE

ADJUSTABLE

Yes

These typical values were obtained under the following conditions:

O2 Concentration: 20.95% Sensor Temperature: 26.07°C Current Output Range: 4-20mA Range Endpoint, Low: 0% Range Endpoint, High: 25% Zero Offset Signal: None Pressure Compensation: None

Typical voltages for new sensors at 25°C:

TYPE OF SENSOR MINIMUM NOMINAL MAXIMUM

Disposable 1.05V 1.39V 1.69V Rechargeable 0.97V 1.29V 1.76V

Near the end of the life of the sensor, the sensor voltage is typically 0.53V (disposable) or 0.48V (rechargeable). At tempera-

tures (T) other than 25°C, multiply the voltages above by (1.025)exp(T-25).

"-" is a minus sign displayed on the left of the display between AL 1 and AL 2.

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HOLD MODE

SECURITY ACCESS ROUTINE

see Figure 3-4

ALARM1

ALARM2

Last displayed value held

ENTER

Sensor Voltage

Display Parameters

ALARM1

ALARM2

%O2

DIAGNOSTICS MODE

%O2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

CARET LIT

see Table 4-7

DISPLAY

%O2

Adjust Parameters (see Section 4-4)

WARNING

Testin

Relays will affect devices connected to them

Exit

ALARM1

ALARM2

ALARM1

ALARM2

ALARM

%O2

Return to HOLD

ENTER

DIAGNOSTIC Mode

ALARM1

ALARM2

ALARM1

ALARM2

ALARM

%O2

Figure 4-2. HOLD and DIAGNOSTICS Modes Flowchart

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4-4 DIAGNOSTICS MODE

Refer to Figure 4-2 on page 4-7, Table 4-7 on page 4-6 and Table 4-8 below. The DIAGNOSTICS mode is used to:

• Check sensor circuit voltages

• Check relays

• Adjust the output current

Enter DIAGNOSTICS Mode

If the instrument is already in HOLD mode, skip step 1 and proceed to step 2.

1. From the RUN mode, press the UP ARROW and DOWN ARROW at the same time to enter the HOLD mode.

2. If the security is activated, enter the security identification (id) code and press ENTER to continue.

Hld, YES, flash briefly, then Hld flashes alternately with the last oxygen reading. The output signal will remain unchanged until the instrument returns to the RUN mode.

a. Raw Sensor Voltage

1. Press DISPLAY and ACK at the same

time to enter DIAGNOSTICS mode.

Tst, d-3, d-4 flash briefly, then the %O

caret lights and the raw sensor

voltage is displayed.

2. Press ENTER at any time to return to

HOLD mode. Press ENTER again to return to RUN mode.

KEY DISPLAY WHAT HAPPENS

DISPLAY "2.13" Scrolls among the DIAGNOSTIC displays ACK Nothing Nothing ALARM 1 "A-1" "On"/ "OFF" Toggles the Alarm 1 relay ON/OFF ALARM 2 "A-2" "On" / "OFF" Toggles the Alarm 2 relay ON/OFF UP ARROW DOWN ARROW CAL Nothing Nothing ENTER "hLd" Drops back to HOLD mode

b. Test Current Output

The current output can be tested (increased or decreased using the ARROW keys) and the actual output will change. When the instrument returns to the RUN mode, the output will return to the previous value.

1. Press DISPLAY until the minus sign () is displayed on left.

"2.13" →"2.14" "2.14" →"2.13"

Table 4-8. DIAGNOSTICS Mode Key Functions

Increases current output or span setting Decreases current output or span setting

c. Linearizing Current Output

For some samples, current output does not track the oxygen reading displayed. The operator can linearize output and store the compensating second-order polynomials in EEPROM. This data will remain and function there as long as the EEPROM is not erased. However, if a "cold boot" is performed, the operator must repeat this linearization routine.

2. Use the ARROW keys to increase or decrease the current output.

4-8 Calibration and Adjustments Rosemount Analytical Inc. A Division of Emerson Process Management

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To determine if current output linearization is necessary, do the following:

1. Connect a separate current meter to the output terminals (any device that will display an accurate current measurement such as a computer input will suffice).

NOTE

Do not simply connect a current measurement meter in parallel with the usual load because this will lead to incorrect readings.

2. Place the instrument in DIAGNOSTIC mode by pressing the UP and DOWN ARROWS, followed by the DISPLAY and ACK keys. The display will show consecutively:

tSt, d-3, d-4, and oxygen input voltage

3. Press the DISPLAY key until the minus sign and a number are displayed. This reading is the current output (in milliamps) as determined by the Model 7003M.

8. Use the UP and DOWN ARROW keys to adjust the actual current output (as noted on the separate meter) to the correct amount. Note that the instrument display does not change.

9. Press ENTER, the instrument displays diA, returns to the DIAGNOSTIC mode, and continues to display the current output.

10. Use the UP and DOWN ARROW keys to adjust the current output to a lower value, representing the low range (the operator may prefer to use 4 mA to represent 0% oxygen).

11. Press CAL (the instrument displays CCL for lower current output setting), and repeat steps 3 and 4 of this procedure.

12. Use the UP and DOWN ARROW keys to adjust the current output to a value higher than the initial calibration value (step 1 of this procedure), representing the higher range (the operator may prefer to set it at

16.72mA to represent 20.9% oxygen.

4. Use the UP and DOWN ARROW keys to increase the display reading, and occasionally, compare the current displayed on both meters (the instrument display and the separate meter).

5. If the two readings are too disparate (different applications require lesser or greater tolerance), do the following 3-point calibration to linearize the current output:

6. Use the UP and DOWN ARROW keys to set the current output to a value halfway up its range. The operator may prefer to set it at a critical measurement point.

7. Press the CAL key. The instrument will flash CCA, illuminate the three right-hand carets, and continue displaying the current output.

Rosemount Analytical Inc. A Division of Emerson Process Management Calibration and Adjustments 4-9

13. Press CAL (the instrument displays CCH for high current output setting), and repeat steps 3 and 4 of this procedure.

To return to the RUN mode, press ENTER twice.

At any time during this procedure, the operator may press the ACK key to reset all calibration coefficients to default values. Pressing DISPLAY at any time during this procedure will cause the instrument to display for a moment the relevant calibration efficient.

The operator may escape the current CALIBRATION and DIAGNOSTIC mode altogether by pressing ENTER twice. Note, all coefficients will return to the default values, and the current calibration procedure must be started over to linearize current output.

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NOTE

The low calibration point must be between the initial calibration point (step 1 of previous procedure) and zero, and the high calibration point must be between the initial calibration point and 20mA.

If the third point calibrated (step 8, previous procedure) is actually another low range (between the initial calibration point and CCL) it will override the original CCL but won't affect the initial calibration.

NOTE

The current output linearizing procedure uses second order polynomials to adjust the output linearity. The correction effect is maximized at the calibration point, and is smoothly diminished towards the endpoints.

d. Test Alarm Relays

1. Disconnect any alarm or ON/OFFControl devices that are connected to the analyzer, before testing.

2. Toggle the relays ON and OFF using the ALARM 1 and ALARM 2 keys.

A-1 ON or A-2 OFF is displayed. The alarm contacts can be heard opening and closing.

3. Connect any alarm or ON/OFFControl devices that were disconnected in step 1.

4. Press ENTER to exit the DIAGNOSTICS mode.

"Hld" flashes alternately with the last oxygen reading and the analyzer returns to HOLD mode.

5. Press ENTER again to return to RUN mode.

4-5 ADJUSTMENTS AND SETTINGS

All operator settings and adjustments are made using the front keypad except if the power jumpers are to be changed. Refer to the following sections:

2-5b Power Connections on page 2-4

NOTE

When alarms are tested manually, any alarm or ON/OFF-Control devices connected to the relays will respond as they would in an alarm condition. The alarm devices may have to be disconnected from the relays for this test.

4-10 Calibration and Adjustments Rosemount Analytical Inc. A Division of Emerson Process Management

3-5d Zero Offset Adjustment on page 3-15

4-4a Raw Sensor Voltage on page 4-8

4-4c Linearizing Current Output on page 4-8

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SECTION 5

THEORY

5-1 PRINCIPLES OF OPERATION

The Model 7003M Percent Oxygen Analyzer consists of an amperometric sensor and analyzer interconnected by a multi-conductor shielded cable. The sensor responds to the partial pressure of oxygen and produces a current signal. The analyzer amplifies and processes the signal, providing readout in percent oxygen and current output.

a. Electrochemical Theory

With the sensor placed in the sample gas, a voltage is applied across the cathode and anode. Sample gas diffuses through the membrane and is reduced at the cathode resulting in a current proportional to the partial pressure of oxygen in the sample.

When no oxygen is present, a small residual sensor current, which can be offset during instrument setup.

5-2 EFFECTS OF SAMPLE CONDITIONS

a. Barometric Pressure

If ambient air is used to calibrate the sensor, a change in barometric pressure can be a significant factor. At 76 cm Hg, the partial pressure of oxygen is 15.9 cm Hg (20.9% of 76 cm Hg). As atmospheric pressure deviates from 76 cm Hg, the partial pressure of oxygen will vary proportionally. The highest partial pressure that can be read by the Model 7003M is 19 cm Hg (25% oxygen at 76 cm Hg).

oxygen without affecting the total barometric pressure.

This relationship can be expressed as :

P atm = Po2 + PH20 = P other,

where:

P atm = total barometric pressure,

Po2 = partial pressure of oxygen,

PH20 = partial pressure of water vapor,

P other = partial pressure of all gases other than oxygen and water vapor

c. Sample Temperature

The rate of oxygen diffusion through the sensor membrane varies with temperature, with a coefficient of about +3% °C (5% °F), causing a corresponding change in sensor current. The instrument continuously monitors temperature with a thermistor in the sensor body, and compensates the output for both sample temperature and membrane permeability.

Because of a slight time lag in the response of the temperature sensor, a rapid temperature change will cause a temporary change in apparent oxygen level, such as might be encountered if the sensor is suddenly exposed to direct sunlight from a shadow.

b. Humidity

If calibrating with humid ambient air, the effect of the partial pressure due to water vapor content should be taken into consideration. High humidity has the effect of reducing the partial pressure of

Rosemount Analytical Inc. A Division of Emerson Process Management Theory 5-1

Extended use of the sensor at low temperatures will shorten the life of the sensor. As the sensor reaches the end of its useful life, distinct step changes in the oxygen reading will be evident as the oxygen level changes.

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748223-K June 2002

d. Interfering Gases

Gases that are reduced or oxidized in the range of 0.5 to 0.8VDC contribute to sensor current and can cause a readout error. Only a few gases have this characteristic. Common gases that should be avoided include SO oxides of nitrogen (NO concentrations of hydrogen sulfide tend to contaminate the sensor, but may not seriously affect oxygen measurement.

If you suspect that any stream components are affecting the operation of the sensor, contact Rosemount Analytical Technical Services.

If contaminated, the rechargeable sensor must be rejuvenated and the disposable sensor must be replaced. Refer to the instructions supplied with the sensor.

5-3 CIRCUIT DESCRIPTIONS

a. Signal Board

The Signal Board is configured to match the type of sensor ordered with the analyzer. If the type of sensor is changed, or the Signal Board is repaired or replaced, verify the rocker switch position (SW1):

Rechargeable Sensor: Close positions 1,4, and 5

2, Cl2, and

). Low-level

Model 7003M

•

+5V (isolated) for other functions for that circuit

There are isolated and non-isolated grounds on the Power Supply Board. TP1 is the non-isolated ground and should be used with TP6 and TP7.

c. Microprocessor Board

The Microprocessor Board is the functional center of the instrument. With the exception of the program chip, no user serviceable functions are on this assembly. If the Microprocessor Board is to be repaired or replaced, note the positions of the configuration jumpers for setting jumpers on replacement board.

An instrument timer circuit monitors instrument power for a power failure, power surge or other outside condition interfering with the microprocessor operation. When conditions return to normal, the circuit will attempt a system restart. If the microprocessor is still capable of operating, both alarm relays will be put into alarm condition, the screen will clear, and the output current will drop to 0 mA. Then the instrument will go through a normal power-up routine and will eventually return to routine operation with alarms and output restored to their normal conditions. The appropriate error code (E-0, etc.) will be displayed until the ACK button is pressed.

Disposable Sensor: Close positions 2,4,

d. Alarm Circuits

and 6

Each alarm activation setpoint is designed

b. Power Supply Board

to be at a different level from the deactivation setpoint:

The Power Supply Board provides:

•

To prevent relay contacts from

•

±12V (non-isolated) for analog

signaling function

•

+5V (non-isolated) for microprocessor and associated logic

chattering if the oxygen level stays around the setpoint.

•

To indicate to the microprocessor whether alarm is HIGH or LOW.

•

To allow for a time lag between the time the alarm is activated and the

•

+24V (non-isolated) for the isolated current function

5-2 Routine Servicing and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

time it is deactivated for ON/OFFControl purposes.

Model 7003M

ROUTINE SERVICING AND TROUBLESHOOTING

Operator Manual

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June 2002

SECTION 6

WARNING

ELECTRICAL SHOCK HAZARD

Servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel.

Relay contacts wired to separate power sources must be disconnected before servicing.

6-1 ROUTINE SERVICING

Most service and maintenance involves cleaning and recharging the sensor. Refer to the instructions supplied with the sensor for recharging and maintenance procedures.

Service is rarely required on the Model 7003M Percent Oxygen Analyzer. Repair is limited to replacement of PCB boards, EPROM and fuses. See Section 7 Replacement Parts.

6-2 TROUBLESHOOTING

Troubleshooting should be referred to qualified service technicians. Refer to Section 5-3 Circuit Descriptions, on page 52, as an aide in isolating a problem.

a. Symptoms

Cannot adjust signal to calibration value

Possible cause

Sensor voltage error

Check/Test

Install know good sensor and verify voltage

Corrective Action

Recharge or replace sensor

Readings not consistent with calibration curve

Possible cause

Incorrect sensor used for application

Check/Test

Verify sensor corresponds with application

Corrective Action

Install new sensor and calibrate with span gas

Possible cause

Sensor temperature incorrect

Check/Test

Sensor temperature should be 0 to 50°C

Calibration error code displayed

Possible cause

Exhausted Sensor

Check/Test

Install know good sensor and isolate

Corrective Action

Recharge or replace sensor

Rosemount Analytical Inc. A Division of Emerson Process Management Routine Servicing and Troubleshooting 6-1

Corrective Action

Install new sensor and calibrate with span gas

Possible cause

Incorrect span gas concentration

Check/Test

Verify span gas concentration

Corrective Action

Install new sensor and calibrate with span gas

Operator Manual

748223-K June 2002

Model 7003M

Error code E-0 displayed

Possible cause

Power interruption, power surge or other outside interference has occurred

Corrective Action

Press ACK. If this symptom occurs frequently, surge-protection is recommended.

Will not read low levels of oxygen

Possible cause

Ambient air leaking into system

Check/Test

Increase sample flow rate, block off flow of gas in and out of flow chamber, and not analyzer response

Corrective Action

If signal increases with test, isolate and seal leak. If signal does not increase, replace or recharge sensor.

Sudden change in output for no apparent reason

Possible cause

Sensor subjected to sudden change in conditions, as when a shadow moves and exposes the sensor to an increase in temperature

Corrective Action

Locate sensor in an area shaded from sunlight and away from cold or warm drafts.

Resolution degrading with time

Possible cause

Sensor exposed to low temperatures.

Check/Test

Per Section 4-4b on page 4-8, check current output of sensor.

If the sensor is degrading, the signal will change in steps as the oxygen level changes instead of changing continuously.

Corrective Action

Relocate sensor or replace more frequently.

6-2 Routine Servicing and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

748223-K

June 2002

SECTION 7

REPLACEMENT PARTS

7-1 CIRCUIT BOARD REPLACEMENT POLICY

In most situations involving a malfunction of a circuit board, it is more practical to replace the board than to attempt isolation and replacement of an individual component. As standard policy, rebuilt boards are available on an exchange basis.

7-2 MATRIX

7003M MODEL 7003M OXYGEN MONITOR*

Code Power

01 115 VAC, 50/60 Hz 05 230 VAC, 50/60 Hz

Code Mounting Options

01 Panel Mount - Standard 07 Wall Mounting Plate w/ Junction Box 08 Two-Inch Pipe Mounting Bracket

Code Gain Setting

50 Signal: High Level (Used with Rechargeable Sensor % Gas) 51 Signal: Low Level (Used with Disposable Sensor % Gas) 99 Signal: Special

Because of the exchange policy covering circuit boards, the following sections on replacement parts do not include individual, circuit board mounted components. If circumstances necessitate replacement of an individual component, which can be identified by inspection or from the schematic diagrams, obtain the replacement component from a local source of supply.

7003M 01 01 50

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 7-1

Operator Manual

748223-K June 2002

7-3 REPLACEMENT PARTS - MODEL 7003M

WARNING

PARTS INTEGRITY

Tampering or unauthorized substitution of components may adversely affect safety of this product. Use only factory documented components for repair

PART NUMBER DESCRIPTION

652630 Signal Board 652640 Power Supply Board 654605 Display/Keypad Board 655195 EPROM 655197 Microprocessor Board 777156 Fuse, 1/4 A, 120V (pkg of 5) 777360 Fuse, 1/8 A, 240 V (pkg of 5) 858728 Arc Suppressor

Model 7003M

When replacing Microprocessor Board PN 652650, replace with Microprocessor Board PN 655197 AND EPROM 655195.

7-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

7-4 REPLACEMENT PARTS - SENSORS

a. Rechargeable Sensors

Sensor:

MATERIAL PART NUMBER

Polypropylene 623371 Polypropylene 623370 (use with Fast Response Kit) Ryton 190408 Ryton 190409 (use with Fast Response Kit)

Sensor Kits (Sensor not included):

DESCRIPTION PART NUMBER USE WITH SENSOR

Submersion, Polypropylene 639904 623371 In-Line Flow, Polypropylene 639905 623371 Fast Response, Polypropylene 639906 623370 Submersion, Ryton 646628 190408 In-Line Flow, Ryton 646629 190408 Fast Response, Ryton 646630 190409

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Sensor Kits (Sensor included):

DESCRIPTION PART NUMBER Submersion, Polypropylene 400011

In-Line Flow, Polypropylene 400012 Fast Response, Polypropylene 400013 Submersion, Ryton 400021 In-Line Flow, Ryton 400022 Fast Response, Ryton 400023

Recharge Kit

Recharge Kit (10 recharges) 191755

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 7-3

Operator Manual

748223-K June 2002

b. Disposable Sensors

Sensor:

MATERIAL PART NUMBER

Polypropylene 623742

Sensor Kits (Sensor not included):

DESCRIPTION PART NUMBER USE WITH SENSOR

Submersion, Polypropylene 623715 623742 In-Line Flow, Polypropylene 623716 623742

Sensor Kits (Sensor included):

DESCRIPTION PART NUMBER

Submersion, Polypropylene 500011 In-Line Flow, Polypropylene 500012

Model 7003M

7-4 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

8-1 RETURN OF MATERIAL

If factory repair of defective equipment is required, proceed as follows:

1. Secure a return authorization from a Rosemount Analytical Inc. Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted.

Rosemount CSC will provide the shipping address for your instrument.

In no event will Rosemount be responsible for equipment returned without proper authorization and identification.

2. Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs during shipping.

3. In a cover letter, describe completely:

•

The symptoms that determined the equipment is faulty.

•

The environment in which the equipment was operating (housing, weather, vibration, dust, etc.).

•

Site from where the equipment was removed.

•

Whether warranty or non-warranty service is expected.

•

Complete shipping instructions for the return of the equipment.

4. Enclose a cover letter and purchase order

and ship the defective equipment according to instructions provided in the Rosemount Return Authorization, prepaid, to the address provided by Rosemount CSC.

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June 2002

SECTION 8

RETURN OF MATERIAL

If warranty service is expected, the defective unit will be carefully inspected and tested at the factory. If the failure was due to the conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount’s option, and an operating unit will be returned to the customer in accordance with the shipping instructions furnished in the cover letter.

For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.

8-2 CUSTOMER SERVICE

For order administration, replacement Parts, application assistance, on-site or factory repair, service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

8-3 TRAINING

A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at:

Rosemount Analytical Inc.

Customer Service Center

1-800-433-6076

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 8-1

Operator Manual

748223-K June 2002

Model 7003M

8-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.

Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller's direct control.

Operator Manual

748223-K June 2002

Model 7003M

Emerson Process Management

Rosemount Analytical Inc. Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd.

1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947

http://www.processanalytic.com

Fisher-Rosemount GmbH & Co.

Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd.

Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount

Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

Emerson 7003M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

LIST OF DRAWINGS

PREFACE

DEFINITIONS

SAFETY SUMMARY

AUTHORIZED PERSONNEL

DOCUMENTATION

COMPLIANCES

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

1-3 SENSORS

1-4 CONDITIONS AFFECTING MEASUREMENT

a. Gas Composition

b. Sample and Cal Gas Pressures

c. Environmental Factors

1-5 FEATURES

1-6 SPECIFICATIONS

a. Performance

b. Physical

c. Electrical

d. Sensors

INSTALLATION

2-1 UNPACKING

2-2 STORAGE

2-3 ANALYZER INSTALLATION

2-4 SENSOR INSTALLATION

a. Analyzer/Sensor Jumper Configuration

2-5 ELECTRICAL CONNECTIONS

a. Sensor Cable

b. Power Connections

c. Current Output Connections

d. Voltage Output Connections

OPERATION

3-1 OVERVIEW

3-2 KEYPAD OPERATION

a. Single and Double Keystroke

b. Display Prompts

c. Error Messages

d. Automatic Return to RUN Mode

e. Preventing Unauthorized Access

f. Sensor Equilibrium

3-3 START-UP

a. Initial Power-Up

b. System Restart

d. Manual Restart

3-4 RUN MODE

b. Acknowledge Alarms

c. Access Other Modes

3-5 SETUP MODE

a. Security Code

c. Range Endpoint Adjustments

d. Zero Offset Adjustment

a. Relay Configured as Alarm

c. Relay Contacts

d. Fail Safe Operation

h. Setting Alarm Setpoints

e. Relay Reset Upon Fatal Error

f. Pressure Effects on Alarms

i. Setting Alarm ON and OFF Levels

CALIBRATION AND ADJUSTMENTS

4-1 FREQUENCY OF CALIBRATION

a. Zero Calibration

b. Span Calibration

4-2 CALIBRATION MODE

Table 4-2. Composition of Dry Atmospheric Air

Table 4-3. Composition of Humid Atmospheric Air

Table 4-4. Barometric Pressure Effect on Apparent Oxygen Concentration

4-3 HOLD MODE

4-4 DIAGNOSTICS MODE

b. Test Current Output

c. Linearizing Current Output

d. Test Alarm Relays

4-5 ADJUSTMENTS AND SETTINGS